Pioneer PDP-R04U, PRO-R04U Schematic

ORDER NO.

PIONEER CORPORATION 4-1, Meguro 1-chome, Meguro-ku, Tokyo 153-8654, Japan

PIONEER ELECTRONICS (USA) INC. P.O. Box 1760, Long Beach, CA 90801-1760, U.S.A.
PIONEER EUROPE NV Haven 1087, Keetberglaan 1, 9120 Melsele, Belgium
PIONEER ELECTRONICS ASIACENTRE PTE. LTD. 253 Alexandra Road, #04-01, Singapore 159936

PIONEER CORPORATION 2003

ARP3178

PDP-R04U

MEDIA RECEIVER

PDP-R04U

PRO-R04U

THIS MANUAL IS APPLICABLE TO THE FOLLOWING MODEL(S) AND TYPE(S).

Model Type Power Requirement Remarks

PDP-R04U TUCK AC120-240V

PRO-R04U KUC AC120V

Please connect it to the PLASMA DISPLAY PDP-504PU, PDP-434PU, PRO-504PU or PRO­434PU, for adjustment and operation inspection.

For details, refer to "Important symbols for good services".

T-ZZK DEC. 2003 printed in Japan

1234

SAFETY INFORMATION

A

This service manual is intended for qualified service technicians; it is not meant for the casual
do-it-yourselfer. Qualified technicians have the necessary test equipment and tools, and have been
trained to properly and safely repair complex products such as those covered by this manual.
Improperly performed repairs can adversely affect the safety and reliability of the product and may
void the warranty. If you are not qualified to perform the repair of this product properly and safely, you
should not risk trying to do so and refer the repair to a qualified service technician.

WARNING

B

This product contains lead in solder and certain electrical parts contain chemicals which are known to the state of California to
cause cancer, birth defects or other reproductive harm.
Health & Safety Code Section 25249.6 – Proposition 65

NOTICE
(FOR CANADIAN MODEL ONLY)
Fuse symbols (fast operating fuse) and/or (slow operating fuse) on PCB indicate that replacement
parts must be of identical designation.

REMARQUE
(POUR MODÈLE CANADIEN SEULEMENT)

C

Les symboles de fusible (fusible de type rapide) et/ou (fusible de type lent) sur CCI indiquent que
les pièces de remplacement doivent avoir la même désignation.

(FOR USA MODEL ONLY)

1. SAFETY PRECAUTIONS

The following check should be performed for the
continued protection of the customer and service
technician.

LEAKAGE CURRENT CHECK

Measure leakage current to a known earth ground

(water pipe, conduit, etc.) by connecting a leakage

D

E

current tester such as Simpson Model 229-2 or
equivalent between the earth ground and all exposed
metal parts of the appliance (input/output terminals,
screwheads, metal overlays, control shaft, etc.). Plug
the AC line cord of the appliance directly into a 120V
AC 60 Hz outlet and turn the AC power switch on. Any
current measured must not exceed 0.5 mA.

Reading should
not be above

0.5 mA

Earth
ground

Device
under
test

Also test with
plug reversed
(Using AC adapter
plug as required)

Test all
exposed metal
surfaces

Leakage
current
tester

AC Leakage Test

ANY MEASUREMENTS NOT WITHIN THE
LIMITS OUTLINED ABOVE ARE INDICATIVE
OF A POTENTIAL SHOCK HAZARD AND
MUST BE CORRECTED BEFORE RETURN­ING THE APPLIANCE TO THE CUSTOMER.

2. PRODUCT SAFETY NOTICE

Many electrical and mechanical parts in the appliance
have special safety related characteristics. These are
often not evident from visual inspection nor the
protection afforded by them necessarily can be obtained
by using replacement components rated for voltage,
wattage, etc. Replacement parts which have these
special safety characteristics are identified in this
Service Manual.

Electrical components having such features are
identified by marking with a
on the parts list in this Service Manual.
The use of a substitute replacement component which
does not have the same safety characteristics as the
PIONEER recommended replacement one, shown in the
parts list in this Service Manual, may create shock, fire,
or other hazards.

Product Safety is continuously under review and new
instructions are issued from time to time. For the latest
information, always consult the current PIONEER
Service Manual. A subscription to, or additional copies
of, PIONEER Service Manual may be obtained at a
nominal charge from PIONEER.

on the schematics and

F

2

1234

PDP-R04U

5678

[ Important symbols for good services ]

In this manual, the symbols shown-below indicate that adjustments, settings or cleaning should be made securely.
When you find the procedures bearing any of the symbols, be sure to fulfill them:

1. Product safety

You should conform to the regulations governing the product (safety, radio and noise, and other regulations), and
should keep the safety during servicing by following the safety instructions described in this manual.

2. Adjustments

To keep the original performances of the product, optimum adjustments or specification confirmation is indispensable.
In accordance with the procedures or instructions described in this manual, adjustments should be performed.

3. Cleaning

For optical pickups, tape-deck heads, lenses and mirrors used in projection monitors, and other parts requiring cleaning,
proper cleaning should be performed to restore their performances.

4. Shipping mode and shipping screws

To protect the product from damages or failures that may be caused during transit, the shipping mode should be set or
the shipping screws should be installed before shipping out in accordance with this manual, if necessary.

A

B

5. Lubricants, glues, and replacement parts

Appropriately applying grease or glue can maintain the product performances. But improper lubrication or applying
glue may lead to failures or troubles in the product. By following the instructions in this manual, be sure to apply the
prescribed grease or glue to proper portions by the appropriate amount.For replacement parts or tools, the prescribed
ones should be used.

C

D

56

PDP-R04U

E

F

7

8

3

1234

CONTENTS

SAFETY INFORMATION..................................................................................................................................... 2

A

B

C

D

E

F

1. SPECIFICATIONS ............................................................................................................................................ 5

2. EXPLODED VIEWS AND PARTS LIST............................................................................................................ 6

2.1 PACKING ...................................................................................................................................................6

2.2 EXTERIOR SECTION................................................................................................................................ 8

2.3 FRONT SECTION.................................................................................................................................... 12

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM..........................................................................................14

3.1 BLOCK DIAGRAM AND SCHEMATIC DIAGRAM ................................................................................... 14

3.1.1 MR MAIN BOARD .............................................................................................................................14

3.1.2 AV BOARD ASSY.............................................................................................................................. 16

3.1.3 POWER SUPPLY UNIT ..................................................................................................................... 18

3.1.4 DTV TUNER BOARD.........................................................................................................................19

3.2 OVERALL WIRING DIAGRAM................................................................................................................. 22

3.3 MR MAIN BOARD ASSY (1/13)............................................................................................................... 24

3.4 MR MAIN BOARD ASSY (2/13)............................................................................................................... 26

3.5 MR MAIN BOARD ASSY (3/13)............................................................................................................... 28

3.6 MR MAIN BOARD ASSY (4/13)............................................................................................................... 30

3.7 MR MAIN BOARD ASSY (5/13)............................................................................................................... 32

3.8 MR MAIN BOARD ASSY (6/13)............................................................................................................... 34

3.9 MR MAIN BOARD ASSY (7/13)............................................................................................................... 36

3.10 MR MAIN BOARD ASSY (8/13)............................................................................................................. 38

3.11 MR MAIN BOARD ASSY (9/13)............................................................................................................. 40

3.12 MR MAIN BOARD ASSY (10/13)........................................................................................................... 42

3.13 MR MAIN BOARD ASSY (11/13)........................................................................................................... 44

3.14 MR MAIN BOARD ASSY (12/13)........................................................................................................... 46

3.15 MR MAIN BOARD ASSY (13/13)........................................................................................................... 48

3.16 AV BOARD ASSY (1/7).......................................................................................................................... 50

3.17 AV BOARD ASSY (2/7).......................................................................................................................... 52

3.18 AV BOARD ASSY (3/7).......................................................................................................................... 54

3.19 AV BOARD ASSY (4/7).......................................................................................................................... 56

3.20 AV BOARD ASSY (5/7).......................................................................................................................... 58

3.21 AV BOARD ASSY (6/7).......................................................................................................................... 60

3.22 AV BOARD ASSY (7/7).......................................................................................................................... 62

3.23 BRIDGE ASSY....................................................................................................................................... 64

3.24 MDR ASSY ............................................................................................................................................66

3.25 SR ASSY ............................................................................................................................................... 68

3.26 FRONT ASSY (1/2)................................................................................................................................ 70

3.27 FRONT ASSY (2/2)................................................................................................................................ 72

3.28 LED ASSY ............................................................................................................................................. 73

3.29 AC SW ASSY and POWER SUPPLY UNIT ...........................................................................................74

3.30 WAVEFORMS ........................................................................................................................................ 76

3.31 VOLTAGES............................................................................................................................................. 77

4. PCB CONNECTION DIAGRAM ..................................................................................................................... 81

4.1 AC SW and MDR ASSYS ........................................................................................................................ 81

4.2 MR MAIN BOARD ASSY ......................................................................................................................... 82

4.3 AV BOARD and SR ASSYS..................................................................................................................... 86

4.4 BRIDGE and MDR ASSYS ...................................................................................................................... 90

4.5 FRONT and LED ASSY ........................................................................................................................... 92

5. PCB PARTS LIST ........................................................................................................................................... 94

6. ADJUSTMENT ............................................................................................................................................. 102

6.1 HOW TO ENTER SERVICE FACTORY MODE...................................................................................... 102

6.2 POSSIBLE CASES WHERE READJUSTMENT IS REQUIRED ........................................................... 102

6.3 USING RS-232C COMMANDS.............................................................................................................. 103

6.4 ADJUSTMENT ITEMS........................................................................................................................... 104

6.5 TRAP SWITCH ...................................................................................................................................... 108

6.6 SERVICING USING ONLY THE MEDIA RECEIVER............................................................................. 109

6.7 SERVICE FACTORY MODE .................................................................................................................. 110

6.8 LIST OF RS-232C COMMANDS ...........................................................................................................124

6.9 OUTLINE OF COMMANDS ................................................................................................................... 127

7. GENERAL INFORMATION........................................................................................................................... 132

7.1 DIAGNOSIS ........................................................................................................................................... 132

7.1.1 TROUBLE SHOOTING.................................................................................................................... 132

7.1.2 DISASSEMBLY................................................................................................................................ 142

7.2 EXPLANATION ......................................................................................................................................145

7.2.1 PROCESSING IN ABNORMALITY .................................................................................................145

7.3 PARTS.................................................................................................................................................... 149

7.3.1 IC ..................................................................................................................................................... 149

7.4 CLEANING............................................................................................................................................. 171

8. PANEL FACILITIES ...................................................................................................................................... 172

4

1234

PDP-R04U

Item Media Receiver, Model: PDP-R04U, PRO-R04U

Reception System (Digital) ATSC Digital TV system

Circuit type 8VSB demodulation
Tuner VHF/UHF VHF 2–13ch, UHF 14–69ch

CATV 2–125ch (Standard Channel Plan, 8VSB only)

Audio format Dolby Digital

Reception System (Analog) American TV standard NTSC system

Circuit type Video signal detection PLL full synchronous detection, PLL digital

synthesizer system

Tuner VHF/UHF VHF 2–13ch, UHF 14–69ch

CATV 1–125ch

Audio multiplex BTSC system

Terminals Rear DTV Antenna 75Ω UNBAL, F Type for DTV in

Antenna A 75 Ω UNBAL, F Type for VHF/UHF/CATV in

Loop out

Antenna B 75 Ω UNBAL, F Type for VHF/UHF/CATV in

Loop out
i.LINK (TS) S400 (2)
INPUT 1 COMPONENT VIDEO in, S-VIDEO in, VIDEO in, AUDIO in, HDMI in
INPUT 2 S-VIDEO in, VIDEO in, AUDIO in
INPUT 3 COMPONENT VIDEO in, AUDIO in, HDMI in
Monitor Out S-VIDEO out, VIDEO out, AUDIO out
Digital Audio Output Optical (1)
VCR Control Output 1
CONTROL IN 1
CONTROL OUT 1

Front INPUT 4 COMPONENT VIDEO in, S-VIDEO in, VIDEO in, AUDIO in,

PC Analog RGB in, AUDIO in

OSD English/French/Spanish/Korean(PDP-R04U)
Power Requirement 110–240 V AC, 50/60 Hz, 44.5 W (0.3 W Standby, 120 V) (PDP-R04U)
Dimensions 420 (W) × 90 (H) × 297 (D) mm (16 /16 (W) × 3 /16 (H) × 11 /16 (D) inches)

99 11

Weight 5.7 kg (12.6 lbs.)

• Design and specifications are subject to change without notice.

Operating instruction

Power cord (2 m/6.6 feet)
(ADG1215)

Remote control unit
(PDP-R04U : AXD1478)
(PRO-R04U : AXD1484)

System cable (3 m/9.8 feet)
(ADF1021)

AA size battery x 2
(Alkaline battery)

Stand
(PDP-R04U : AXG1013)
(PRO-R04U : AXG1009)

Screw x 4 (for stand)

(PMB409120FZK)

Screw hole cap x 4
(PDP-R04U : AMR3363)
(PRO-R04U : AMR3386)

VCR controller x 1

(1.8 m/5.9 feet) (ADH1024)

Coaxial cable (0.15 m/0.49 feet) x 1
(Already set at the rear of the Media
Receiver) (ADE1190)

5678

1. SPECIFICATIONS

A

B

C

D

56

PDP-R04U

7

E

F

5

8

1234

2. EXPLODED VIEWS AND PARTS LIST

NOTES:

A

2.1 PACKING

B

C

10

Parts marked by "NSP" are generally unavailable because they are not in our Master Spare Parts List.
The mark found on some component parts indicates the importance of the safety factor of the part.
Therefore, when replacing, be sure to use parts of identical designation.
Screws adjacent to mark on product are used for disassembly.
For the applying amount of lubricants or glue, follow the instructions in this manual.
(In the case of no amount instructions, apply as you think it appropriate.)

21

7

6

24

27

x4

12

8

32

19

33

1, 2, 3, 13, 28

22

4

30

34

35

15

36

35

D

20

25

E

F

23

20

19

6

1234

PDP-R04U

>

5678

PACKING parts List

Mark

No. Description Part No.

1 Operating Instruction See Contrast table(2)
(English/French/Spanish)
2 Operating Instruction(English) See Contrast table(2)
3 Operating Instruction(English) ARB1559
4 Remote Contorol Unit See Contrast table(2)
5• • • • • •

6 System cable (3m) ADF1021

7 Power Cord ADG1215
8 VCR Controller (1.8m) ADH1024
9• • • • • •
NSP 10 AA size Battery (LR6) VEM1021

11 • • • • • •
12 Screw Hole Cap See Contrast table(2)
13 Operating Instruction HDMI ARE1373
(English/French/Spanish)
14 • • • • • •
15 Stand Assy See Contrast table(2)

Mark

No. Description Part No.

21 Top Pad (Cardboard) AHB1247
22 Accessory Box AHC1051
23 Curton See Contrast table(2)
NSP 24 Literature Bag AHG1303
25 Laminated Sheet Bag AHG1332

26 • • • • • •
27 Vinyl Bag AHG1337
NSP 28 Card VRY1132
29 • • • • • •
30 Battery Cover AZA7424

31 • • • • • •
32 Screw PMB40P120FZK
33 Vinyl Bag AHG1340
NSP 34 Stand See Contrast table(2)
NSP 35 Stand Cushion AEB1390

36 Laminated Sheet Bag AHG1334

A

B

16 • • • • • •
17 • • • • • •
18 • • • • • •
19 Protector AHA2305
20 Cardboard Spacer AHB1246

(2) CONTRAST TABLE

PRO-R04U/KUC and PDP-R04U/TUCK are constructed the same except for the following:

Mark NO Symbol and Description PDP-R04U/TUCK PRO-R04U/KUC

1 Operating Instruction

(English/French/Spanish)
2 Operating Instruction(English) Not used ARB1556
4 Remote Contorol Unit AXD1478 AXD1484

12 Screw Hole Cap AMR3363 AMR3386
15 Stand Assy AXG1013 AXG1009

23 Curton AHD3170 AHD3192

NSP 34 Stand AMR3352 AMR3382

ARE1367 Not used

C

D

E

56

PDP-R04U

F

7

8

7

1234

2.2 EXTERIOR SECTION

73

13

98

73

2

18

B

73

73

59

73

Q

85

Bb

J

14

73

73

76

52

104

103

50

22

I

N

M

81

69

62

Bb

E

K

17

S

D

55

51

73

99

102

11

79

83

73

78

P

D

32

H

1

Z

73

F

4

36

30

43

67

NON-CONTACT

76

34

67

71

78

110

73

109

45

SIDE

73

105

107

See Note (3)

114

113

73

69

78
73

72

101

106

71

73

S

73

57

44

CONTACT SIDE

A

70

70

97

I

9

B

73

73

C

O

73

49

12

57

5

G

46

111

96

57

73

15

D

96

63

57

61

31

73

A

73

C

D

H

E

89

F

111

88

Refer to
"2.3 FRONT PANEL SECTION".

20

72

100

108

35

40

38

73

H

73

E

19

P

27

10

7

M

21

73

A

K

57

60

58

73

70

111

29

111

O

K

95

N

22

73

70

86

37
73

75

73

56

41

65

78

47

60

39

26

25

69

64

76

42

50

64

L

73

C

39

39

93

33

Ba

23

E

J

28

L

24

39

G

A

F

73

8

I

59

Q

F

54

Ba

16

G

65

76

66

Z

112

6

58

73

34

67

8

1234

PDP-R04U

>

>

5678

EXTERIOR SECTION parts List

Mark

No. Description Part No.

1 AV BOARD Assy See Contrast table(2)
2 MDR Assy AWZ6778
3• • • • • •
4 SR Assy AWZ6780
5 BRIDGE Assy AWZ6803

No. Description Part No.

Mark

51 Gasket C ANK1719
52 Gasket D ANK1720
53 Nylon Binder AEC-093
54 PCB Holder AEC1097
55 Spacer AEC1256

A

6 FRONT Assy See Contrast table(2)
7 LED Assy AWZ6805
8 MR MAINBOARD ASSY AWV2028
9 DTV TUNER BOARD AXY1064

10 POWER SUPPLY UNIT AXY1065

11 AC Inlet (CN1) AKP1249
12 Flexible Cable (J201) ADD1209
13 Flexible Cable (J202) ADD1209
14 Flexible Cable (J203) ADD1210
15 Flexible Cable (J204) ADD1211

16 Flexible Cable (J205) ADD1244
17 Flexible Cable (J206) ADD1213
18 Flexible Cable (J207) ADD1214
19 12p Housing Wire (J109) ADX2849
20 8p Housing Wire (J110) ADX2850

21 Wire Harness (J103) ADX2831
22 Earth Wire (J104) ADX2832
23 15p Housing Wire (J105) ADX2833
24 3p Housing Wire (J107) ADX2836
25 3p Housing Wire (J108) ADX2837

26 16p Housing Wire (J112) ADX2859
27 7p Housing Wire (J113) ADX2860
28 Fan Motor 60*25l AXM1041
29 Fan Motor 40*10.5l AXM1042
30 Base Chassis See Contrast table(2)

56 Locking Card Spacer AEC1429
57 Nyron Rivet AEC1671
58 Wire Saddle AEC1745
59 Reuse Wire Saddle AEC1945
60 Edge Saddle AEC1946

61 Barrier B AEC1956
62 Mini Card Spacer AEC1959
63 Mini Clump AEC1961
64 Reuse Clamp AEC1963
65 Mini Cramp AEC1971

66 Card Space A BEC1120
67 Screw ABZ30P080FZK
68 • • • • • •
69 Hexagon Headed Screw BBA1051
70 Screw BBB30P080FMC

71 Washer Faced Nut BBN1005
72 • • • • • •
73 Screw BBZ30P060FZK
74 • • • • • •
75 Screw BBZ30P140FMC

76 Screw See Contrast table(2)
77 • • • • • •
78 Screw BPZ30P100FZK
79 Screw CBZ30P080FZK
80 • • • • • •

B

C

D

31 Front Chassis See Contrast table(2)
32 Terminal Panel See Contrast table(2)
33 Center Stay ANG2564
34 Leg Assy AXG1012
35 BS Holder ANG2566

36 SR Holder ANG2567
37 Fan Holder ANG2568
38 Fan Holder 40 ANG2600
39 Insulation Rubber AEB1377
40 Fan Cushion AEB1388

41 Barrier A AEC1936
42 Metal Bonnet Top See Contrast table(2)
43 Metal Bonnet Bottom See Contrast table(2)
44 Barrier C AEC1962
45 Barrier D AEC1965

46 Front Shield A ANG2615
47 Front Shield C ANG2637
48 • • • • • •
49 Gasket A ANK1717
50 Gasket B ANK1718

81 Screw PMZ26P060FZK
82 • • • • • •
NSP 83 Serial Label ARW1100
84 • • • • • •
85 Caution Label AAX2999

86 Trap Switch ASG1089
87 • • • • • •
88 Power SW Caution AAX3040
NSP 89 TAB Film AEC1976
90 • • • • • •

91 • • • • • •
92 • • • • • •
93 FFC Cushion AEB1395
94 • • • • • •
95 DVI Cushion AEB1396

96 Fiber Washer WA32W100E025
97 OPT Connector Top AKT1096
98 Solder Warning Label AAX2644
NSP 99 Label See Contrast table(2)
100 Energy Star Label See Contrast table(2)

E

F

56

PDP-R04U

7

8

9

IN

S

E

R

V

IC

E

O

N

L

Y

M

O

N

IT

O

R

O

U

T

V

C

R

C

O

N

T

R

O

L

A

A

N

T

E

N

N

A

/C

A

B

L

E

B

O

U

T

IN

IN

O

U

T

C

O

N

T

R

O

L

O

U

T

S

-V

ID

E

O

S

-V

ID

E

O

R

-A

U

D

IO

-L

R

-A

U

D

IO

-L

V

ID

E

O

V

ID

E

O

IN

P

U

T

2

1234

Mark

No. Description Part No.

101 Pulg Cord (0.15m) ADE1190
102 Silicon Sheet HDMI AEB1379

A

103 Surkit Boad Spaser AEC1964
104 Heat Sink HDMI ANH1618
105 HDMI Shield ANG2646

106 Gasket G ANK1724
107 Gasket F ANK1722
108 PCB Spacer AEC1104
109 DDCON Shield ANG2648
110 FE Shield S ANG2647

111 Screw ABZ30P060FMC

B

112 6p Housing Wire (J114) ADX2881
113 SR -Cover AAX3066
NSP114 Binder AEC-036

(2) CONTRAST TABLE

PRO-R04U/KUC and PDP-R04U/TUCK are constructed the same except for the following:

Mark NO Symbol and Description PDP-R04U/TUCK PRO-R04U/KUC

1 AV BOARD Assy AWZ6802 AWZ6819

C

6 FRONT Assy AWZ6804 AWZ6820
30 Base Chassis ANA1771 ANA1772
31 Front Chassis ANB1862 ANB1865
32 Terminal Panel ANC2352 ANC2355

42 Metal Bonnet Top ANE1615 ANE1621
43 Metal Bonnet Bottom ANE1616 ANE1622
76 Screw BMZ30P060FNI BMZ30P060FZK

NSP 99 Label AAX2974 AAX3012

100 Energy Star Label AAX3030 Not used

(3) NOTE

D

SR-IN

SR-OUT

· Please insert SR-Cover in SR control terminal.
(SR-Cover is not attached to initial shipment product.)

E

SR-Cover

F

10

Binder

PDP-R04U

1234

5678

A

B

C

D

E

56

PDP-R04U

F

7

8

11

1234

2.3 FRONT SECTION

A

6

B

22

5

18

25

1

J

3

26

25

2

11

23

9

4

10

11

19

11

7

21

24

C

14

13

D

12

27

12

12

16

12

17

15

23

10

8

20

NOTES ON ASSEMBLING (for the PRO-R04U only)

· The screws (11) are fixed to the parts (19) and (7) with screw-

E

19

11

7

20

fixing adhesive.

· If the screws (11) are loosened for servicing, reattach the
screws after servicing as follows:

1. Tighten the screws (11) with normal torque until the parts

indicated by A show slight indentation.

2. Loosen the screws (11) by one-eighth of a turn until the

11

indentation of the parts indicated by A return to normal.

3. Check that the parts (19) and (20) are securely attached.

4. Apply one or two drops of screw-fixing adhesive between

(11) and (19) and between (11) and (7).

A

F

12

1234

A

PDP-R04U

>

5678

FRONT SECTION parts List

Mark

No. Description Part No.

1 AC SW ASSY AWZ6783

2 POWER SWITCH (S9341) ASG1093
3 SW Holder ANG2565
4 SW Spring ABH1109
5 Power Button AAD4124

Mark

No. Description Part No.

16 Door See Contrast table(2)
17 Front Panel A See Contrast table(2)
18 Front Panel B See Contrast table(2)
19 Door Cap L See Contrast table(2)
20 Door Cap R See Contrast table(2)

A

6 Front Panel Assy See Contrast table(2)
7 Magnet Holder ANG2579
8 Magnet AMF1003
9 Dumper AXA1017
10 Special Screw 3x8 ABA1309

11 Screw BPZ30P080FZK
12 Screw See Contrast table(2)
13 Panel A See Contrast table(2)
14 Panel B See Contrast table(2)
15 Door Inner Cover See Contrast table(2)

(2) CONTRAST TABLE

21 Sealing Sheet See Contrast table(2)
22 Pioneer Badge See Contrast table(2)
23 Door Cushion See Contrast table(2)
24 Lens For LED AMR3353
25 Screw APZ30P080FMC

26 Screw BMZ30P060FMC
27 Serial Sheet AAX2609

PRO-R04U/KUC and PDP-R04U/TUCK are constructed the same except for the following:

Mark NO Symbol and Description PDP-R04U/TUCK PRO-R04U/KUC

6 Front Panel Assy AXG1002 AXG1016
12 Screw JPZ20P035FNI JPZ20P035FZK
13 Panel A AAK2803 AAK2809
14 Panel B AAK2804 AAK2811
15 Door Inner Cover AAK2807 AAK2810

16 Door AAN1469 AAN1470
17 Front Panel A AMB2771 AMB2774
18 Front Panel B AMB2767 AMB2775
19 Door Cap L AMR3360 AMR3367
20 Door Cap R AMR3361 AMR3368

B

C

21 Sealing Sheet AAL2448 AAL2458
22 Pioneer Badge VAM1124 PAN1376
23 Door Cushion AEB1391 AEB1394

D

E

F

56

PDP-R04U

7

8

13

1234

3. BLOCK DIAGRAM AND SCHEMATIC DIAGRAM

3.1 BLOCK DIAGRAM AND SCHEMATIC DIAGRAM

3.1.1 MR MAIN BOARD

A

MR MAIN BOARD ASSY

A

SP_R/L,STB_MT
CN7455
AKM1201

CST1,KEYSCAN,,SR_OUT

HDMI_RCH/LCH

TXD_WR,RXD_WR

JA6881
AKP1232

B

JA6801
AKP1232

CN6951
AKM1201

CN7454
AKM1201

RBS/GBS/BBS[0:7],
CKBS,DEBS,VBS,HBS
TXD_DT,RXD_DT

MAIN_Y/C

C

PCA_H/V

MAINC_Y/PB/PR R/G/B_OUT

R/G/B_TXT_MAIN

D

HD/VD_TXT

HD RMIx

IC6881

SII9993CTG100

HDMI Rx

IC6801

SII9993CTG100

RDV2/GDV2/BDV2[0:7],

CKDV2,DEDV2,VDV2,HDV2 SYSC

RDV1/GDV1/BDV1[0:7],

CKDV1,DEDV1,VDV1,HDV1

R/G/B_DA_MAIN HD/VD_MAIN
TD0_IC1M

RESETX

SEL

IC7452

TC74VHC126FT

IC6802

TC74VHC

157

MAINC_Y

LPF MAIN

IC6401

SM5301BS

IC7451

TC74VHC08FT

IC6803

PCM1742KE

Y/C SEP.

CHROMA DEC.

MAIN

IC6107

PD0278A

RESETX1

RESETX2
TRST

RESETX3

IC6101

TC7W126FU

HD/VD_TXT_MAIN

AD MAIN

IC6402

AD9883AKST-110

SEL

IC6951

PD6435A

LPF SUB

SUBC_Y/PB/PR R/G/B_OUT

SUB_Y/C

E

CN7453
AKM1232

TRST,RST R/G/B_DA_SUB
TCK,TMS

UARTTXD,UARTRXD

DBI,SDIJTAG,TRST_IC3,TDI

IC6601

SM5301BS

SUBC_Y

SYSCLK1S HD/VD_TXT_SUB

Y/C SEP.

CHROMA DEC.

SUB

IC6255

PD0278A

AD SUB

IC6602

AD9883AKST-110

HD/VD_SUB

F

14

PDP-R04U

1234

5678

MAIN_UCOM[1:176]

X6101

DCT115

LK1S RST_ASIC,

IC7202

TC74VHC125

FLD_MAIN RESETX

IC7202

TC74VHC125

MAIN UCOM

IC7207

MB91F35APMTGE1

RST2

IC7209

TC74VHC08FT

CN7402

AKM1234

A

B

RA/GA/BA/HD/CK/DE/VD/FLD_MAIN UARTTXD

SYNC SEL

IC6405

TC74VHC126FT

SYANC SEP.MIN

IC6404

BA7078AF

HD1_MAIN

SYLNC SE

IC6408

HD_MAIN

HD/VD
_MAIN

RA/GA/BA/HD/CK/DE/VD_MAIN TD0_IC3

RA/GA/BA/HD/CK/DE/VD_SUB

HD/VD_SUB FIELD

HD_SUB

RA/GA/BA/HD/CK/DE/VD/FLD_SUB

TC74VHC126FT

RA/GA/BA/HD/CK_MAIN

RA/GA/BA/HD/CK_SUB

SYNC SEL

IC6607

TC74VHC126FT

SYNC SEP.SUB

IC6604

BA7078AF

SYNC SEL

IC6603

TC74VHC126FT

HD1_SUB

HD1/VD1_MAIN

PLLHD/PLLHOLD/CLAMP_MAIN

PLLHD/PLLHOLD/CLAMP_SUB

HD1/VD1_SUB

HD2/VD2_SUB H,DE

UARTRXD

HD2/VD2_MAIN

I/P

IC7004

PE5326A

RESIZE MIX

IC7101

PE5855A

SYSCLK_2

RA/GA/BA/
RB/GB/BB_IC2

RA/GA/BA TMDS[0:7]
VD0

CLK0

RESET IC

IC7210

PST3612UR

SDRAM

IC7001,IC7002

HY57V643220CT-7

SD RAM

IC7002

HY57V643220CT-7

IC7003

TC74LCX125FT

SYSCLK_3

SDRAM
IC7151

MBM20PL3200BE70PFV

SDRAM
IC7152

MBM20PL3200BE70PFV

DVI TX
IC7401

SII170BCLG64

FIELD2

LOGIC

IC7404

TC74VCX08FT

CN7401

AKP1216

C

D

E

DE0,HD0

PDP-R04U

56

7

LOGIC

IC7403

TC74VCX574FT

F

15

8

1234

3.1.2 AV BOARD ASSY

A

ANTENNA

IN

ANTENNA

IN

U7501

VXF1022

U7502

VXF1022

IC7502

4066AFT

SCL/SDA_AV

IC7503

CXA2064TC74HC

AIR_V

AIR_R/L

AIR_V2

DT_Y

DT_C

DT_R

DT_L

IC8903

M306V7

CCD

UCOM

DT_V

RXD1

TXD1

OUT1

R/G/B

SCL/SDA_AV

B

C

VIDEO1

VIDEO2

VIDEO3

VIDEO1

COMPONENT

VIDEO3

COMPONENT

Y

PB

PR

Y

PB

PR

D

V1_Y/C/V

V1_R/L

V2_Y/C/V

V2_R/L

V3_R/L

CN9502

AKM1201

CN8653

AKM1201

IC8002

CXA2069Q

SCL/SDA_AV

MAINC_Y SUBC_Y

HD_TXT_MAIN VD_TXT_MAIN

SCL/SDA_AV SUB_CC_EN

Y_COMP4 YUVD1_G

VIDEO4

COMPONENT

VIDEO4

E

G

PB_COMP4 YUVD1_B

PR_COMP4 YUVD1_R

41

44

47

32

V4_Y V4_Y

30

V4_C V4_C

25

V4_V V4_V

20

V4_R V4_R

22 29

V4_L V4_L

FRONT
ASSY

PC

F

16

18

PC_LCH PC_LCH

16

PC_RCH PC_RCH

7

PC_H

5

PC_V

5

PC_R

3

PC_G

1

PC_B

CN9504

B6B-PH-SM3-TBB

10

7

4

19

21

26

31

33

35

44

PC_H

46

PC_V

5

PC_R

3

PC_G

1

PC_B

CN8654
B6B-PH-SM3-TBB

PDP-R04U

SCL/SDA_AV

IC8005

AN1585

IC8906
ML6428

1234

5678

OPT_R

OPT_L

CN8657

16

14

18

20

12

10

5

To/From
DTV MOD

IC8003

TC4052BFT

AUDIO SW

AUDIO_L

AUDIO_R

VOUT

COUT

YOUT

NJM12904

IC8901

TC7W126FU

IC8004

MONITOR

OUT

TXD (TO_DSUB9)
RXD (FROM_DSUB9)

IC8705

24LC01B

IC8702

HD64F3687FP

UIF UCOM

IC8704

TC7W126FU

AV BOARD ASSY

B

HDMI_RCH 5

UIF_UCOM

AUDIO_R 1
AUDIO_L 3

HDMI_LCH 7

SCL_AV
SDA_AV

RXD_WR
TXD_WR

CN8652

AKM1201

28–30, 33–38,
48,50

32
31

30
29

A

B

C

PC_V

MAINC_Y/PB/PR

SUBC_Y/PB/PR

IC8001

TC7WH123FU

IC8909

PE5398

IR_BLASTER

IC8910

NJM2283

IC8905

TA1287

HD_TXT_MAIN 2

PN2
MAIN_Y
MAIN_C
SUB_Y
SUB_C
WE_TXT
VD_TXT_MAIN
HD_TXT_MAIN

R_TXT_MAIN
G_TXT_MAIN
B_TXT_MAIN

R_DA_MAIN
G_DA_MAIN
B_DA_MAIN

R_DA_SUB
G_DA_SUB
B_DA_SUB

MAINC_Y
MAINC_PB
MAINC_PR
SUBC_Y
SUBC_PB
SUBC_PR

DSUB_DET
PCA_V
PCA_H

3
49
47
39
37

4
5
29
30
31
45
43
41

35
34
33

25
27
23
15
17
13

1
6
7

CN8651

AKM1201

D

E

F

56

PDP-R04U

7

8

17

1234

3.1.3 POWER SUPPLY UNIT

A

17V

12V

DCDC

CONVERTER

12V 5V

IC8507

DCDC

CONVERTER

12V 1.25V

IC8509

B

RELAY

PD_TRG

RELAY

C

AC_DET

AC DET

DCDC

CONVERTER

6.5V 3.35V

IC8508

UP COM

12V 3.3V V+3ILK

IC8503

32V

AV

V+5V_A

Q8512
Q8513

Devices

SW

3.3V

1.5V1.5V

SW

Q8511

12V 9V

Regulaters

IC8504
IC8505

6.5V

2.5V

DCDC

12V

CONVERTER

IC8502

PSW1 PD_DCDC1

3.3V

2.5V

US_ILK_SW

IC9701

Bridge

SR

V+3STB

REG

FAN

DTV

FRONT

V+5V_A

UP COM

V+5STB

IC8501

SW

IC8506

US_REC_SW

V+3STB

ACTIVE

AC_DET

V+5V_AV

V+3STB

UIF MICRO
COMPUTER

V+3COM

SENSOR

MDRPower Ass'y

TMDS

D

STB

RELAY

AV Ass'y

V+5V_AV

V+3STB

E

F

6.5V

Regulaters

IC7454

IC7453

Main Ass'y

Main

Devices

(STB/REC)

5V

3.3V

PD_DCDC1

PSW1
PD_MAIN
RELAY

Devices

Main

MICROCOMPUTER

Main

(ON)

V+3COM

18

1234

PDP-R04U

5678

3.1.4 DTV TUNER BOARD

A

L/R In

Port #1

Port #2

1.2V

DC Powers

ATSC

IEEE1394

2 port PHY

(TSB41AB2)

2.5V

3.3V5V12V

IEEE1394

ceLynx

(TSB42AA4)

13.5MHz

Thomson NIM
(DTF8603(H))

UART

(COM1, 2)

EEPROM

(256kb)

Boot Flash

(512kb*8)

User Flash

(8Mb*16)

MK2772

T1

SP1

Local Bus

T2

VCXOCTRL

SYS_CLK(27M)
ACLK

TL955

Single Chip

SoC

Demux,

MP@HL Dec,

AC-3 Dec,

CPU

(564Pin, BGA)

EJTAG

H/V sync

Digital 16bit YPbPr

Audio D/A

(CS4335)

IE C6095B

Aux Video

DDR RAM

(32MBx4)

PCI bus

Audio A/D

(CS5330)

SPDIF Tx

(CS8405)

H/V
Y
Pb
Pr
L
R
Optic SPDIF

CVBS
S-Video

PCI Slot for
Network I/F

B

C

D

E

F

56

PDP-R04U

7

8

19

1234

A

Interface spec between MAIN and DRM (110 Pin Connector)

Torerance

Symbol Dir. Voltage Description Remark

VOH_MIN VOL_MAX
VIH_MIN VIL_MAX

Tolerance

Control

TxD Out 3.3V UART TTL 2.4 0.4
RxD In 3.3V UART TTL 2.0 0.8
TxD Out 3.3V UART for Update TTL 2.4 0.4

B

RxD In 3.3V UART for Update TTL 2.0 0.8
Reset In 3.3V Module reset TTL (Active low) 2.0 0.8
Ready Out 3.3V ready flag TTL (Active low) 2.4 0.4
Request Out 3.3V request flag TTL (Active low) 2.4 0.4

Video

Y0 Out 3.3V digital output TTL 2.4 0.4
Y1 Out 3.3V ” TTL 2.4 0.4
Y2 Out 3.3V ” TTL 2.4 0.4
Y3 Out 3.3V ” TTL 2.4 0.4
Y4 Out 3V ” TTL 2.4 0.4

C

Y5 Out 3.3V ” TTL 2.4 0.4
Y6 Out 3.3V ” TTL 2.4 0.4
Y7 Out 3.3V ” TTL 2.4 0.4
PbPr0 Out 3.3V ” TTL 2.4 0.4
PbPr1 Out 3.3V ” TTL 2.4 0.4
PbPr2 Out 3.3V ” TTL 2.4 0.4
PbPr3 Out 3.3V ” TTL 2.4 0.4
PbPr4 Out 3.3V ” TTL 2.4 0.4
PbPr5 Out 3.3V ” TTL 2.4 0.4

D

PbPr6 Out 3.3V ” TTL 2.4 0.4
PbPr7 Out 3.3V ” TTL 2.4 0.4
Hsync Out 3.3V ” TTL (Active low) 2.4 0.4
Vsync Out 3.3V ” TTL (Active low) 2.4 0.4
CLK Out 3.3V ” TTL (Active low) 2.4 0.4
CVBS Out 1Vp-p analog output Buffer out +/-10%
Y Out 1Vp-p ” Buffer out +/-10%
C Out 0.286Vp-p

” Buffer out +/-10%

burst level

E

Audio

Lout Out 2Vrms FS analog output <1kohm +/-5%
Rout Out 2Vrms FS ” <1kohm +/-5%
Lin In 2.8Vrms FS analog input >10kohm
Rin In 2.8Vrms FS ” >10kohm

Power

12V In 12V ± 5%
5V In 5V ± 5%

3.3V In 3.3V ± 5%

3.3V2 In 3.3V for network standby ± 5%

F

2.5V In 2.5V ± 5%

1.31V In 1.31V ± 5%

20

1234

PDP-R04U

5678

Pin Assignment

Pin No. name in/out Remarks Pin No. name in/out

1 D_GND 56 5V
2 Y1 out 57 5V
3 Y2 out 58 P_GND
4 Y0 out 59 P_GND
5 5D_GND 60 12V
6 Y6 out 61 P_GND
7 Y7 out 62 1.31V
8 PbPr7 out 63 1.31V

9 Y5 out 64 P_GND
10 PbPr0 out 65 P_GND
11 PbPr1 out 66 2.5V
12 PbPr6 out 67 2.5V
13 Y4 out 68 2.5V
14 D_GND 69 P_GND
15 Y3 out 70 P_GND
16 D_GND 71 P_GND
17 H sync out 72 3.3V
18 D_GND 73 3.3V
19 V sync out 74 3.3V
20 D_GND 75 3.3V
21 CLK out 76 P_GND
22 D_GND 77 P_GND
23 A_GND 78 P_GND
24 C out 79 P_GND
25 A_GND 80 3.3V2
26 Y out 81 P_GND
27 A_GND 82 A_GND
28 CVBS out 83 R_in in
29 A_GND 84 A_GND
30 P_GND 85 L_in in
31 3.3V2 for Network standby 86 A_GND
32 P_GND 87 R_out out
33 P_GND 88 A_GND
34 P_GND 89 L_out out
35 P_GND 90 Reserved
36 3.3V 91 Reserved
37 3.3V 92 Reserved
38 3.3V 93 D_GND
39 3.3V 94 SPDIF in
40 P_GND 95 D_GND
41 P_GND 96 READY out
42 P_GND 97 REQUEST out
43 2.5V 98 RESET in
44 2.5V 99 D_GND
45 2.5V 100 TXD2 out
46 P_GND 101 RXD2 in
47 P_GND 102 D_GND
48 1.31V 103 TXD out
49 1.31V 104 RXD in
50 P_GND 105 D_GND
51 12V 106 PbPr2 out
52 P_GND 107 PbPr3 out
53 P_GND 108 PbPr4 out
54 5V 109 PbPr5 out
55 5V 110 D_GND

Remarks

for Network standby

MAIN > DTV

MAIN > DTV

DTV > MAIN

DTV > MAIN

DTV > MAIN for update
MAIN > DTV for update

DTV > MAIN
MAIN > DTV

A

B

C

D

E

F

56

PDP-R04U

7

8

21

1234

3.2 OVERALL WIRING DIAGRAM

A

G

B

C

G 1/2 - G 2/2

(PDP-R04U : AWZ6804)
(PRO-R04U : AWZ6820)

FRONT
ASSY

D

B

AV BOARD ASSY
(PDP-R04U : AWZ6802)
(PRO-R04U : AWZ6819)

E

F

F

B 1/7 - B 7/7

SR ASSY
(AWZ6780)

LED ASSY

H

(AWZ6805)

22

1234

PDP-R04U

5678

DTV TUNER BOARD

I

(AXY1064)

BRIDGE ASSY

D

(AWZ6803)

NOTES: • When ordering service parts, be sure to refer to “EXPLODED VIEWS

and PARTS LIST” or “PCB PARTS LIST”.

• The > mark found on some component parts indicates the importance of

the safety factor of the part.
Therefore, when replacing, be sure to use parts of identical designation.

• : The power supply is shown with the marked box.

A

B

C

POWER SUPPLY UNIT

K

(AXY1065)

A

A 1/13 - A 13/13

MR MAIN
BOARD ASSY
(AWV2028)

D

E

AC SW ASSY

J

(AWZ6783)

56

PDP-R04U

MDR ASSY

E

(AWZ6778)

7

8

F

23

1234

3.3 MR MAIN BOARD ASSY (1/13)

A

A 1/13

B

NOT USED

MR MAIN BOARD ASSY (AWV2028)

¶ GR BLOCK

C SYNC SEP.

C

V SYNC SEP.

D

13/13A

E

F

A

13/13

A 1/13

24

1234

PDP-R04U

5678

A

NOT USED

2/13-9/13,

A

11/13-13/13

B

(Ghosts Reduce IC)

C

D

E

56

PDP-R04U

2/13, 3/13A

F

A 1/13

7

8

25

1234

3.4 MR MAIN BOARD ASSY (2/13)

A

A 2/13

MR MAIN BOARD ASSY (AWV2028)

¶ MICHEL MAIN BLOCK

8/13, 11/13A

A

7/13, 8/13

4/13, 7/13, 8/13

A

B

C

+polality

4/13, 13/13A

D

E

A

1/13, 3/13

F

A 2/13

26

1234

PDP-R04U

5678

A

7/13A

B

3/13A

A

13/13

13/13

A

13/13

A

C

D

E

1/13, 3/13-9/13, 11/13-13/13

A

A

3/13, 6/13, 7/13, 13/13

56

PDP-R04U

3/13, 8/13, 13/13

A

13/13

A
A

3/13
3/13, 8/13, 9/13, 13/13A

7

F

A 2/13

27

8

1234

3.5 MR MAIN BOARD ASSY (3/13)

A

9/13A

A

7/13, 9/13

A

5/13,
7/13,

+polality

5/13,

13/13

A

2/13

A

9/13

B

C

D

E

F

A 3/13

28

1/13, 2/13A

PDP-R04U

1234

5678

A 3/13

MR MAIN BOARD ASSY (AWV2028)

¶ MICHEL SUB BLOCK

13/13A

A

B

C

A

1/13, 2/13, 4/13-9/13, 11/13-13/13

2/13, 6/13, 7/13, 13/13A

A

2/13, 8/13, 13/13
2/13

A
A

8/13
2/13, 8/13, 9/13, 13/13

A

A

13/13

A

13/13

D

E

F

56

PDP-R04U

A 3/13

7

8

29

1234

3.6 MR MAIN BOARD ASSY (4/13)

A

A 4/13

MR MAIN BOARD ASSY (AWV2028)

¶ AD MAIN BLOCK

13/13A

A

13/13

H : FILTER THROUGH
L : FILTER ON

H : Ch B (TEXT RGB)
L : Ch A (COMPONENT / PC RGB)

B

13/13A

A

C

D

13/13

E

F

13/13A

A 4/13

30

SELECTOR

A

2/13, 4/13, 7/13, 8/13

2/13, 7/13, 8/13

A

8/13A

1234

PDP-R04U